Butchering processes for the beef clod

ABSTRACT

A method for mass-production butchering of a chuck roll of beef includes: sectioning the beef clod into a first portion and a second portion substantially along a natural seam, the first portion comprising triceps brachii long head muscle and essentially being free of triceps brachii lateral head muscle, and the second portion comprising triceps brachii lateral head muscle and essentially being free of triceps brachii long head muscle; and sectioning the first portion generally with or parallel to the grain into a first set of separate portions. Another method for mass-production butchering of a beef clod may include: sectioning the beef clod into a first portion and a second portion substantially along a natural seam, the first portion comprising the teres major; and sectioning the first portion generally with or parallel to the grain into a first set of separate portions.

CROSS-REFERENCE TO RELATED APPLICATION

The benefits of Provisional Application No. 61/059,270 filed Jun. 5,2008 and entitled “Butchering Processes for the Beef Clod” are claimedunder 35 U.S.C. §119(e), and the entire contents of this provisionalapplication are expressly incorporated herein by reference thereto.

FIELD OF THE INVENTION

The invention relates to a butchering process for meat products. Moreparticularly, the invention relates to a butchering process for theshoulder/clod portion of a beef carcass.

BACKGROUND OF THE INVENTION

In the United States, the organized grading of cattle and beef hasbecome particularly important in the promotion and marketing of qualityproducts. Administered by the United States Department of Agriculture,the grading system is used to assign a distinct level of quality tocattle carcasses.

Carcass beef grades include a “yield grade” and a “quality grade.” Theyield grade, denoted by the numbers 1 through 5, generally refers to thedegree of cutability of the carcass and serves as an indicator of theamount of closely trimmed (½ inch fat or less), boneless retail cutsexpected to be derived from the major wholesale cuts of the carcass.“Yield Grade 1” represents the highest degree of cutability. The qualitygrade, on the other hand, separately indicates the palatability of thelean. Carcasses of steers and heifers may be graded as Prime, Choice,Select, Standard, Commercial, Utility, Cutter, and Canner, in descendingorder of quality; carcasses of cows may receive any of these gradesexcept Prime. Bullock carcasses may be graded as Prime, Choice, Select,Standard, and Utility. Steers are considered male bovines castrated whenyoung and which have not begun to develop the secondary physicalcharacteristics of bulls, while heifers are considered young, such asless than 3 year old immature female bovines that have not developed thephysical characteristics typical of cows, e.g., have not borne a calf.Cows are considered female bovines that have developed throughreproduction or with age, the physical characteristics typical of maturefemales, and bullocks are considered young, such as under approximately24 months of age, male bovines that have developed or begun to developthe secondary physical characteristics of bulls.

The highest quality grade, USDA Prime, is reserved for beef withabundant marbling (defined as flecks of fat within the lean muscle),thus providing a juicy and flavorful meat that also is tender. USDAPrime, for example, may have more than 8% intramuscular fat. Only asmall percent of all graded carcass beef qualifies as USDA Prime. Aswould be expected, Prime beef is favored by hotels and restaurants, is asuccessful commercial export product from the United States, and also isavailable through retail sales to discriminating consumers. Because itrepresents the highest quality, beef certified as USDA Prime commandsthe highest prices in the market.

The carcass typically refers to both sides of the animal, whereas a siderefers to half of the carcass including both a frontquarter and ahindquarter. From the standpoint of profitability the hindquarter cutsof the carcass, which represent about half of a side of a beef carcass,traditionally have been greatest in demand. In particular, thehindquarter includes the full loin with the short loin and sirloin, theround, flank, and kidney knob. Thus, the hindquarter is the source ofthe well known beef cuts including the top loin steak, T-bone steak,porterhouse steak, tenderloin roast or steak (such as chateaubriand orfilet mignon), top sirloin steak, sirloin steak, tenderloin roast orsteak, beef tri-tip, round steak, top round roast or steak, and rumproasts. The frontquarter, which represents the other half of a side of abeef carcass, includes the chuck, rib, plate, brisket and shank.Products typically produced from the frontquarter include cuts such asthe rib roast or steak, rib eye roast or steak, back ribs, skirt steak,and whole brisket. The beef chuck, shoulder/clod, although used for suchcuts as a “Flat Iron,” “Petite Tender,” and “Shoulder Center,” is notconsidered to be among the wholesale cuts that is most profitable and indemand. Beef from the beef chuck typically is transformed into lowercost ground beef chuck for example for use in producing ground beefchuck patties.

Once a carcass has been graded as Prime, each of the cuts from thecarcass retain that designation. Thus, cuts from both the frontquarterand hindquarter are graded Prime, including the less profitable Primechuck. There exists a need to make use of the chuck to produce steaksinstead of simply being used as roasts or being ground into ground beefchuck. Moreover, there exists a need to make use of the Prime chuck toproduce Prime steaks instead of simply being ground into Prime groundbeef chuck. Because of the demand for the more costly cuts of Primebeef—which for example restaurants and hotels prefer to offer tocustomers—the ability to make use of Prime chuck for steaks may lead toenhanced profitability derived from this portion of the carcass. Therehas been substantial industry interest in enhancing the value of thefrontquarter. For example, scientists from the University of Nebraskaand the University of Florida even conducted a study for the Cattlemen'sBeef Board and analyzed more than 5,500 muscles of the beef chuck andround to assist in developing new beef products. Commercialization ofthe “Flat Iron” steak, a shoulder top blade steak cut from the chuck, issaid to have resulted from the study. Nevertheless, the chuck is complexbecause of the number of muscles and associated fibers that do not runin the same direction as each other. Thus, despite the efforts to dateas described above, there remains a need for additional methods ofproducing products from the beef chuck, shoulder/clod.

The “fabrication” of the beef carcasses is conducted in mass-productionoperations by beef packers, who harvest finished cattle purchased fromfeedlots and create primal, subprimal, and sometimes consumer-readycuts. The beef then is distributed to purveyors/processors or retailersfor further sale. Thus, there is a need for additional methods ofproducing products from the beef chuck, shoulder/clod for use in themass-production operations.

SUMMARY OF THE INVENTION

The invention relates to a method for mass-production butchering of abeef clod including: sectioning the beef clod into a first portion and asecond portion substantially along a natural seam, the first portioncomprising triceps brachii long head muscle and essentially being freeof triceps brachii lateral head muscle, and the second portioncomprising triceps brachii lateral head muscle and essentially beingfree of triceps brachii long head muscle; and sectioning the firstportion generally with or parallel to the grain into a first set ofseparate portions. The method may further include sectioning the secondportion generally with or parallel to the grain into a second set ofseparate portions. In addition, the method may further include removingfrom at least one of the first and second portions excess materialselected from the group consisting of fat, sinue, and connective tissueto expose a lean side thereof.

In addition, in some exemplary the method may further includemechanically tenderizing separate portions of the first set, wherein theseparate portions of the first set are mechanically tenderized byneedling on at least one side thereof or wherein the separate portionsof the first set are mechanically tenderized by needling on both sidesthereof. In some embodiments, the method may further includemechanically tenderizing separate portions of the second set, whereinthe separate portions of the second set are mechanically tenderized byneedling on at least one side thereof or wherein the separate portionsof the second set are mechanically tenderized by needling on both sidesthereof. Moreover, in some exemplary embodiments, the method may furtherinclude releasably forming separate portions of the first set into asubstantially arcuate shape, wherein the arcuate shape is maintained bytwine and/or by pins. Also, the method may further include releasablyforming separate portions of the second set into a substantially arcuateshape, wherein the arcuate shape is maintained by twine and/or by pins.

In some exemplary embodiments, the method further includes wrappingseparate portions of the first set and/or separate portions of thesecond set in an outer layer selected from the group consisting of fat,bacon, and prosciutto.

The natural seam may include fat in some embodiments. In some exemplaryembodiments, the method further includes removing a vein between thefirst and second portions.

Moreover, in some exemplary embodiments, the method may further includecoupling the first set of separate portions with edible glue.

The invention further relates to a roast formed by the aforementionedmethod for mass-production butchering of a beef clod.

The invention further relates to a london broil formed by theaforementioned method for mass-production butchering of a beef clod.

In addition, the invention relates to a method for mass-productionbutchering of a beef clod including: sectioning the beef clod into afirst portion and a second portion substantially along a natural seam,the first portion comprising the teres major; and sectioning the firstportion generally with or parallel to the grain into a first set ofseparate portions. The invention further relates to a roast formed bythis method. The invention further relates to a london broil formed bythis method.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Typically, meat is cut against the grain, i.e., the muscle fibers of themeat, to provide a softer consistency and better eating experience.Otherwise, typically, if meat is cut parallel to the grain, it will havea stringy and fibrous consistency even if it is properly cooked. Forexample, typically a brisket that has been cut against the grain has asoft consistency while a brisket cut generally with or parallel to thegrain has a chewy consistency. Nonetheless, the methods disclosed hereinadvantageously cut meat generally with or parallel to the grain toachieve a desirable, soft consistency.

The chuck is generally the shoulder region of the animal, and includespart of the neck and backbone, the first five ribs (U.S.packer/processors typically make the chuck/rib break between the 5th and6th ribs), as well as portions of the shoulder blade and upper arm. Itcan weigh over 100 lbs.

Among the cuts derived from the chuck is the beef chuck, shoulder/clodwhich typically weighs between 13 and 21 lbs. An item #114 beef chuck,shoulder/clod (The Meat Buyer's Guide: Beef, Lamb, Veal, Pork, andPoultry. North American Meat Processors Association; John Wiley & Sons,Inc., New Jersey, 2007), for example, is a boneless piece of meat formedof a muscle system disposed anterior to the 6th rib.

Among the muscles included in the clod are (1) latissimus dorsi,infraspinatus, triceps brachii long head, triceps brachii lateral head,tensor fasciae antibrachii and optionally (2) the trapezius, cutaneoustrunci, teres major, and minor muscles over the humerus. Various cuts ofmeat from the #114 include the “Flat Iron” (infraspinatus), “PetiteTender” (teres major), and “Shoulder Center” (triceps brachii longhead).

In accordance with a first exemplary method, mass production butcheringwill now be described for the item #114 beef chuck, shoulder/cloddescribed above making use of an item #114E beef chuck, shoulder/clod,arm roast (The Meat Buyer's Guide: Beef, Lamb, Veal, Pork, and Poultry.North American Meat Processors Association; John Wiley & Sons, Inc., NewJersey, 2007). Item #114E is a portion of an item #114 beef chuck,shoulder/clod and includes (1) the triceps brachii long head and tricepsbrachii lateral head and optionally may include (2) muscles includingthe triceps brachii medial head and tensor fascia antibrachii. A variantof item #114E, known as Item #114E PSO: 1 and sometimes referred to asthe “Clod Heart,” includes only the triceps brachii long head and aportion of the triceps brachii lateral head muscles. Item #114E may besectioned along a natural seam so that the triceps brachii long head andtriceps brachii lateral head are separated from one another in differentportions. Item #1114E beef shoulder, arm steaks may be formed by cuttingthe separated triceps brachii long head from item #114E across thegrain. However, in accordance with the method disclosed herein,preferably the separated triceps brachii long head from item #114Einstead is cut generally with or parallel to the grain to create aplurality of individual portions. Moreover, the separated tricepsbrachii lateral head from item #114E also may be cut generally with orparallel to the grain to create a plurality of roasts and/or a pluralityof london broils.

In accordance with another exemplary method, mass production butcheringwill now be described for an item #114 beef chuck, shoulder/clod makinguse of a #114F beef chuck, shoulder tender (The Meat Buyer's Guide:Beef, Lamb, Veal,

Pork, and Poultry. North American Meat Processors Association; JohnWiley & Sons, Inc., New Jersey, 2007). Preferably, an item #114F beefchuck, shoulder tender is prepared from item #114 by cutting item #114along a natural seam to separate the teres major muscle. Note that a#114F PSO: 1 may be prepared by trimming the item #114F to bepeeled/denuded, surface membrane removed (90% lean exposed) with amaximum average thickness of surface fat of 0.125 inch (3 mm). Further,note that an item #1114F beef shoulder tender, portioned, is in the formof individual steaks prepared by cutting an item #114F across the grain.However, in accordance with the method disclosed herein, item #114Finstead is cut generally with or parallel to the grain to create aplurality of roasts and/or a plurality of london broils.

In each of the above-mentioned embodiments, the natural seam may be aseam of fat therebetween that may be intermuscular fat or intramuscularfat. Morever, fat, sinue, and connective tissue, may be trimmed toexpose the lean and produce a denuded muscle or muscle system. Themuscle or muscle system may be cut into separate portions whichpreferably are suitably sized for roasts and/or london broils. In anexemplary embodiment, the portions formed in the above-mentionedembodiments may be cut from the triceps brachii long head, generallywith or parallel to the grain as specified above, each suitably sized asa roast or london broil.

In each of the above-mentioned embodiments, the method may includeremoving a vein between the first and second portions and/or couplingseparate portions with edible glue.

In one exemplary embodiment, portions may be cut from the tricepsbrachii long head (e.g., two portions), or teres major, to be used as apot roast or for other purposes.

After or before the portions are cut in the exemplary embodimentsdescribed herein, optionally the portions are needled. In particular,jaccarding (also known as needling and blade tenderizing) is known as atechnique for piercing meat for tenderizing. A double jaccardingmachine, for example, needles a piece of meat on both sides thereof. Inan exemplary embodiment, the portions cut from the triceps brachii longhead or teres major are individually needled on each side thereof afterthe portions are cut. While the needle marks may be visible in meat inthe raw state, advantageously the marks are not necessarily visible inthe meat once cooked.

In some embodiments, raw portions produced for example from the tricepsbrachii long head or teres major may be tied with butcher's twine forshaping and compacting, which also provides an attractive presentationto the cuts. The tying, for example, may permit such a raw portion tohave a generally circular or otherwise arcuate shape such as an oblongshape. Alternatively, such a shape may be achieved by clamping the rawmeat using pins. Also, in some embodiments, such raw meat may be wrappedin fat, bacon, or prosciutto.

Moreover, in some embodiments, some portions may be ground to produceground beef.

In some embodiments, the portions may be thinly sliced into pieces witha thickness between about 2 mm and about 4 mm. Such thin slices areknown as “shabu-shabu” (which then may be cooked for example in hotwater or broth). In one exemplary embodiment, the triceps brachii longhead or teres major is chilled to facilitate slicing, and then thinlysliced instead of being cut entirely into portions with substantiallygreater thickness.

The beef chuck, shoulder/clod and portions cut therefrom according to anexemplary embodiment may be injected with salt(s) such as sodiumchloride, calcium chloride, and/or sodium phosphate in solution (i.e.,in a saline solution) and/or other enhancers for enhanced moisture andenhanced flavor. In some exemplary embodiments, the beef chuck,shoulder/clod and portions cut therefrom may be pounded.

In some exemplary embodiments, the beef chuck, shoulder/clod andportions cut therefrom may be marinated.

It should be emphasized that although the sectioning of an item #114beef chuck, shoulder/clod has been described above, other forms of abeef chuck derived from the shoulder/clod may be used.

Moreover, the beef chuck, shoulder/clod and portions cut therefrom maybe aged before being cut or after being cut as applicable.

Large beef portions such as roasts and london broils are contemplated.In some exemplary embodiments, minute steaks, sandwich steaks, frysteaks, and steak on a bun also ultimately may be derived from themethods herein.

While various descriptions of the embodiments are described above, itshould be understood that the various features can be used singly or inany combination thereof. Therefore, this invention is not to be limitedto only the specifically preferred embodiments depicted herein. Further,it should be understood that variations and modifications within thespirit and scope of the invention may occur to those skilled in the artto which the invention pertains. Accordingly, all expedientmodifications readily attainable by one versed in the art from thedisclosure set forth herein that are within the scope and spirit of theembodiments disclosed herein are to be included as further embodiments.The scope of the methods and products is accordingly defined as setforth in the appended claims.

1-25. (canceled)
 26. A method for butchering a beef clod comprising: sectioning the beef clod into a first portion and a second portion substantially along a natural seam, the first portion comprising triceps brachii long head muscle and essentially being free of triceps brachii lateral head muscle, and the second portion comprising triceps brachii lateral head muscle and essentially being free of triceps brachii long head muscle; and sectioning the first portion into a first set of separate portions.
 27. The method of claim 26, wherein the sectioning of the first portion is generally with or parallel to the grain.
 28. The method of claim 26, further comprising: sectioning the second portion generally with or parallel to the grain into a second set of separate portions.
 29. The method of claim 26, further comprising: removing from at least one of the first and second portions excess material selected from the group consisting of fat, sinue, and connective tissue to expose a lean side thereof.
 30. The method of claim 26, further comprising: mechanically tenderizing separate portions of the first set.
 31. The method of claim 28, further comprising: mechanically tenderizing separate portions of the second set.
 32. The method of claim 26, further comprising: releasably forming separate portions of the first set into a substantially arcuate shape.
 33. The method of claim 32, wherein the arcuate shape is maintained by twine.
 34. The method of claim 28, further comprising: releasably forming separate portions of the second set into a substantially arcuate shape.
 35. The method of claim 34, wherein the arcuate shape is maintained by pins.
 36. The method of claim 26, further comprising: wrapping separate portions of at least one of the first set and the second set in an outer layer selected from the group consisting of fat, bacon, and prosciutto.
 37. The method of claim 26, wherein the natural seam comprises fat.
 38. The method of claim 26, further comprising: removing a vein between the first and second portions.
 39. A roast formed by the method of claim
 26. 40. A london broil formed by the method of claim
 26. 41. A method for butchering a beef clod comprising: sectioning the beef clod into a first portion and a second portion substantially along a natural seam, the first portion comprising teres major muscle; and sectioning the first portion generally with or parallel to the grain into a first set of separate portions.
 42. A roast formed by the method of claim
 41. 43. A london broil formed by the method of claim
 41. 44. The method of claim 41, wherein the first set of separate portions includes at least one separate portion with a thickness between about 2 mm and about 4 mm.
 45. A method for butchering a beef clod comprising: separating the beef clod along a natural seam into (i) a first portion comprising triceps brachii long head muscle and essentially being free of triceps brachii lateral head muscle and (ii) a second portion comprising triceps brachii lateral head muscle and essentially being free of triceps brachii long head muscle; and removing from the first portion excess material selected from the group consisting of fat, sinue, and connective tissue to expose a lean side thereof; wherein the first portion is configured and dimensioned as a cut selected from the group consisting of a roast and a london broil. 